Systems and methods for in process heating for direct energy deposition applications

1. A system used to additively manufacture an object layer-by-layer using direct energy deposition (DED), the system comprising:

a base having a first surface where the object is formed, and a second surface disposed on a side of the base opposite the first surface;

a depositor configured to deposit material layer-by-layer on the first surface of the base or a previously deposited layer of the object;

an energy source configured to selectively direct an energized beam at the material to fuse a new layer of the material to a previously formed layer; and

a heating element in direct physical contact with at least a portion of the second surface of the base and configured to conductively supply heat to the base.

2. The system of claim 1 , wherein the heating element comprises a plurality of tubular heating elements.

3. The system of claim 1 , wherein the base includes a tubular passageway.

4. The system of claim 3 , wherein the heating element comprises a plurality of tubular heating elements configured and arranged to fit within the tubular passageway and extend along a length of the tubular passageway.

5. The system of claim 1 , wherein a temperature of the base is 100 to 200 degrees Celsius above ambient temperature.

6. The system of claim 1 , wherein a temperature of the base is within 100 to 200 degrees Celsius of a melting temperature of the material.

7. A system used for direct energy deposition of layers of a material to repair a pre-existing component using direct energy deposition (DED), the system comprising:

a depositor configured to deposit material layer-by-layer on the pre-existing component or a previously deposited layer of material on the pre-existing component;

an energy source configured to selectively direct an energized beam at the material to fuse a new layer of the material to the pre-existing component or to a previously formed layer on the pre-existing component; and

a heating element extending through passageways within the pre-existing component and configured to supply heat to the pre-existing component, the heating element including heat tubing configured to circulate a heated fluid, and a heat-controlled bath apparatus connected to the tubing.

8. The system of claim 7 , wherein a temperature of the pre-existing component is 100 to 200 degrees Celsius above ambient temperature.

9. The system of claim 7 , wherein a temperature of the pre-exiting component is within 100 to 200 degrees Celsius of a melting temperature of the material.

10. A method of depositing layers onto a base using direct energy deposition (DED), the method comprising:

conductively heating the base using a heating element in direct physical contact with a first surface of the base;

depositing a layer of material on a second surface of the base or on a previously deposited layer;

providing energy to the material after each layer is deposited, the energy being provided by an energy source that forms an energized beam directed at the material;

melting the material; and

allowing the material to solidify to bond the material to the second surface of the base or the previously deposited layer;

wherein the first surface is opposite the second surface.

11. The method of claim 10 , wherein the heating step is carried out by a plurality of heating elements configured and arranged to fit within and/or extend along a length of the base.

12. The method of claim 10 , wherein the heating step includes heating the base to 100 to 200 degrees Celsius greater than ambient temperature prior to the depositing step.

13. The method of claim 10 , wherein the heating step includes heating the base to a temperature such that a difference between the temperature of the base and a melting temperature of the material being applied to the base is reduced to 100 to 200 degrees Celsius.

14. The method of claim 10 , wherein the energy source is selected from a group consisting of a laser and an electron beam.

15. The method of claim 10 , further comprising:

monitoring heat of the base to determine a temperature of the base prior to the depositing step.